Milling machine
Machine downtime tracking on a milling machine records condition, stoppages and error messages directly from the control and sensors. Operators see why a machine has stopped, increase availability and resolve faults faster, including through remote access by the manufacturer.
Milling machine at a glance
Most frequent in the projects on this page
Use cases
Users in these projects
Verified projects featuring Milling machine
Security gap closed: how XITASO strengthens the cyber resilience of the DMG MORI CELOS X platform
Optimised precision through the ifm moneo Cloud and IO-Link technology
Increased efficiency through data-based machine monitoring
ITK Transparency-Toolkit in action: determining OEE at the Bosch Rexroth plant
Digital transformation at Groupe Renault
Smart and remote services: machine connectivity is the foundation
Machine downtime tracking and condition data for milling machines
In the solution examples, in.hub connects every machine in a mixed machine park, either via built-in interfaces or via retrofitted sensors. The MaDoW app records the condition, duration and cause of every stoppage, and employees classify the events themselves. ITK's Transparency Toolkit, the size of a toolbox, collects more than 40 signals from the machine control, including part counter, machine status and error messages, and supports OPC UA, MQTT, AMQP and DDS. At Benzinger, ifm IO-Link sensors monitor spindles, energy consumption, vibration, flow and fill level, analysed in the moneo Cloud. For remote service, INSYS icom installs a router in each machine that sets up an encrypted VPN connection.
The examples come from mechanical and plant engineering, automation and automotive, typically for OEE analysis, condition monitoring and remote service. With in.hub, a power tool manufacturer revealed clamping errors on milling machines that were rare but caused significant production losses. At its Lohr plant, Bosch Rexroth uses the ITK toolkit to determine the OEE of a milling machine as its central key figure. The CHIRON Group accesses its customers' machines via VPN when faults occur and schedules the replacement of wear parts according to actual wear.
Podcast episodes featuring Milling machine
Machine downtime tracking for milling machines: frequently asked questions
How does machine downtime tracking work for milling machines?
Downtime tracking continuously records whether a milling machine is producing, being set up or standing still, and why. For a power tool manufacturer, in.hub connected every machine to an IIoT platform regardless of make or age. The MaDoW app logs the duration and cause of each stoppage, and employees give feedback and assign the cause. This is how clamping errors were identified as the reason for significant production losses, for example.
How is the OEE of a milling machine determined?
OEE is calculated from availability, performance and quality: OEE = availability x performance x quality. At Bosch Rexroth's Lohr plant, ITK installed its Transparency Toolkit directly on a milling machine and collected more than 40 signals from the control during production. An interactive dashboard shows OEE together with parts produced, scrap and availability. A fault signal explains low values and can send warnings to the responsible staff.
How does remote access to a milling machine work?
For remote service, the milling machine is made accessible to the manufacturer's service team via an encrypted VPN connection. At the CHIRON Group, an INSYS icom MRX 5 router is permanently installed in every machine. Service staff see error messages, programs and control data directly instead of asking for them over the phone, and can intervene if needed. Using the same connection, CHIRON also offers condition-based maintenance with its ConditionServices.
How secure are connected milling machines?
Connected milling machines are as secure as the testing of their system components, interfaces and protocols. DMG MORI offers digital applications for milling machines with CELOS X and had XITASO examine the latest version in a penetration test on the machine. The experts validated existing measures, described their findings in a security report and recommended further steps. A management summary rated the level of cyber resilience.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
IIoT Use Case user group
What no project tells you
What did the project cost? Which sensor didn't survive in the field? How did you get maintenance on board? 300+ industrial users discuss questions like these with each other every month, openly and without vendors in the room.
Frequent topics in these projects, bring your questions:
- Condition Monitoring
- Digital Documentation
- Corrective maintenance
Online every month
Alternating tech and business focus
Users only
No sales pitches, exchange under NDA
300+ members
OT, IT and IIoT leads from industry
